fuses MERCEDES-BENZ SPRINTER 2006 Owner's Manual

Component Page
Ignition Lock Switch................... 8W-40
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Instrument Panel Socket................ 8W-41
Intake Air Pressure Sensor.............. 8W-30
Intake Air Temperature Sensor........... 8W-30
Interference Suppression Capacitor........ 8W-42
Interior Lamps....................... 8W-44
Interior Light Switches................. 8W-44
Interior Lighting Connector.............. 8W-44
Intrusion Sensors..................... 8W-39
Kickdown Switch...................... 8W-30
Lamp Relays......................... 8W-50
Lateral Acceleration Sensor.............. 8W-35
License Plate Lamps................... 8W-51
Lockeres............................ 8W-31
Low Fuel Pressure Sensor............... 8W-30
Low Pressure Switch................... 8W-42
Map/Reading Lamp Switch.............. 8W-44
Marker Lamp Connector................ 8W-51
Marker Lamps..................... 8W-50, 51
Mass Air Flow Sensor.................. 8W-30
Master Door Lock Switch............... 8W-61
Metering Pump....................... 8W-42
Microphone Connector.................. 8W-55
Multi-Function Switch......... 8W-50, 52, 53, 54
Optional Equipment Relay.............. 8W-11
Oxygen Sensor....................... 8W-30
Panic Alarm Switch.................... 8W-39
Parking Brake Switch.................. 8W-35
Power Distribution Center.............. 8W-10
Power Mirror Motors................... 8W-62
Power Mirror Switch................... 8W-62
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Radio............................... 8W-47
Radio Antenna........................ 8W-47
Radio/Cellular Antenna................. 8W-55
Rain Sensor.......................... 8W-53
Rain Sensor Control Module............. 8W-53
Reading Lamp Connector............... 8W-44
Rear Window Defogger Relay............ 8W-48
Recirculated Air Solenoid Valve........... 8W-42
Refrigerant Pressure Sensor............. 8W-42
Relay Block.......................... 8W-11
Rollover Switch....................... 8W-42
Rollover Switch Assembly............... 8W-42
Roof A/C Blower Fuses................. 8W-42
Roof A/C Blower Stage Relays............ 8W-42
Roof A/C Blowers...................... 8W-42
Roof A/C Compressor Fuse.............. 8W-42Component Page
Roof A/C Control Module................ 8W-42
Roof A/C Fan Fuse.................... 8W-42
Roof A/C Switch....................... 8W-42
Roof A/C Temperature Setting Control..... 8W-42
Roof Fan Motor....................... 8W-42
Roof Fan Switch...................... 8W-42
Roof Thermotronic Control Module........ 8W-42
SKREEM Antenna.................... 8W-39
SKREEM Transponder................. 8W-39
Seat Belt Switch...................... 8W-43
Seat Belt Tensioners................... 8W-43
Security System Module................ 8W-39
Sentry Key Remote Entry Module......... 8W-39
Shifter Assembly...................... 8W-31
Siren............................... 8W-41
Speakers............................ 8W-47
Speed Control Switch.................. 8W-33
Splices.............................. 8W-70
Starter Motor........................ 8W-21
Starter Motor Relay................... 8W-21
Steering Angle Sensor.................. 8W-35
TCS Switch.......................... 8W-35
Tail Lamp Assemblies.................. 8W-51
Temperature Sensor................... 8W-42
Thermotronic Diode.................... 8W-42
Time Delay Relay..................... 8W-44
Towing/Intrusion Sensor On/Off Switch..... 8W-39
Trailer Tow Connector.................. 8W-54
Trailer Tow Control Module.............. 8W-54
Transmission Control Module............ 8W-31
Transmission Relay.................... 8W-31
Turn Signal Relay..................... 8W-52
Turn Signal Switch.................... 8W-50
Turn Signal/Anti-Theft Alarm Relays...... 8W-39
Turn Signals......................... 8W-52
Warm Air Auxiliary Control Module....... 8W-42
Warm Air Auxiliary Heater Assembly...... 8W-42
Washer On/Off Switch.................. 8W-53
Washer Pump Motor-Front.............. 8W-53
Water Cycle Valve..................... 8W-42
Water In Fuel Sensor.................. 8W-30
Wheel Speed Sensors................... 8W-35
Window Defogger Module-Rear........... 8W-48
Window Defogger Switch-Rear........... 8W-48
Window Defoggers..................... 8W-48
Wiper Motor-Front.................... 8W-53
Wiper On/Off Relay.................... 8W-53
Wiper Switch......................... 8W-53
Wiper/Turn Signal/Engine Start Control
Module................... 8W-30, 31, 52, 53
8W - 02 - 2 8W-02 COMPONENT INDEXVA

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Fuel Injector No. 1 BK Engine Compartment 13
Fuel Injector No. 2 BK Engine Compartment 12,13
Fuel Injector No. 3 BK Engine Compartment 12,13
Fuel Injector No. 4 BK Engine Compartment 12,13
Fuel Injector No. 5 BK Engine Compartment 13
Fuel Level Sensor BK Underbody-Middle 51
Fuel Pressure Sensor BK Engine Compartment 12
Fuel Pressure Solenoid (Except OBD) BK Engine Compartment-Rear 11
Fuel Pump BK 4
Fuel Pump Relay BK N/S
Fuel Quantity Control Valve N/S
Fuel Quanitity Control Valve (OBD) 11
Fuel Shutdown SolenoidN/S
Fuel Temperature Sensor Engine Compartment 13
Fuse Block No.1 C1 Under Fuse Block No.1 31
Fuse Block No.1 C2 BK Under Fuse Block No.1 31
Fuse Block No.1 C3 BK Under Fuse Block No.1 31
Fuse Block No.1 C4 BK Under Fuse Block No.1 31
Fuse Block No.1 C5 BK Under Fuse Block No.1 31
Fuses (Fuse Block No. 1) Steering Column 28
Fuses (Fuse Block No. 2) Under Driver Seat 35
Fuses (Fuse Block No. 3) Under Driver Seat N/S
Fuses (Fuse/Relay Block) Under Driver Seat 35,36
Fuses (PDC) Battery Area 8
Generator No.1 Engine Compartment 15
Generator No.2 Engine Compartment-Right 2,14
Glow Plug Control Module C1 BK Engine Compartment-Left
Front1
Glow Plug Control Module C2 BK Engine Compartment-Left
Front1
Glow Plug No. 1 On Engine 15
Glow Plug No. 2 On Engine 15
Glow Plug No. 3 On Engine 15
Glow Plug No. 4 On Engine 15
Glow Plug No. 5 On Engine 15
Headlamp Adjust Switch BK Instrument Panel 25
Headlamp Assembly-Left BK On Front Of Vehicle (Left
Side)3
Headlamp Assembly-Right BK On Front Of Vehicle (Right
Side)3
Heat Exchanger Switch BK Engine Compartment N/S
Heated Seat Module-Driver BK Under Driver Seat 4
Heated Seat Module-Passenger BK Under Passenger Seat 4
Heated Seat Switch-Driver BK On Driver Seat 20
VA8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5

Fig. 41 ROOF A/C FUSES
8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONVA

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
CIGAR LIGHTER OUTLET
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
REMOVAL.............................2
CIRCUIT BREAKER
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIRCUIT
BREAKER............................2
FUSE BLOCK #1
DESCRIPTION..........................2
OPERATION............................3
REMOVAL.............................3
INSTALLATION..........................3FUSE BLOCK #2
DESCRIPTION..........................3
OPERATION............................3
POWER DISTRIBUTION CENTER
DESCRIPTION..........................3
OPERATION............................3
POWER OUTLET
DESCRIPTION..........................3
OPERATION............................4
DIAGNOSIS AND TESTING - POWER OUTLET . 4
REMOVAL.............................4
INSTALLATION..........................4
RELAY
DESCRIPTION..........................4
OPERATION............................5
DIAGNOSIS AND TESTING - RELAY.........5
REMOVAL.............................5
INSTALLATION..........................5
POWER DISTRIBUTION
DESCRIPTION
This section describes the power distribution com-
ponents used on this model as well as the methods in
which battery voltage and charging system voltage is
distributed throughout the vehicle. The power distri-
bution system for this vehicle consists of the follow-
ing major components which are covered in further
detail later in this section:
²Fuseblock #1
²Fuseblock #2
²Power Distribution Center (PDC)
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Cartridge fuses
²Relays
Following are general descriptions and theory of
operation for the major components in the power dis-
tribution system. Refer to Wiring for the location of
complete circuit diagrams for the various power dis-
tribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the standard and optional factory-in-
stalled electrical and powertrain, chassis, safety,
security and convenience systems. At the same time,
the power distribution system was designed to pro-
vide easy access to these electrical distribution points
for the vehicle technician to use when conducting
diagnosis and repair of faulty circuits. The power dis-
tribution system can also prove useful for the addi-
tion of electrical circuits that may be required to
operate accessories that the vehicle owner may
choose to have installed in the aftermarket.
CIGAR LIGHTER OUTLET
DESCRIPTION
The cigar lighter outlet is installed in the instru-
ment panel, near the center of the instrument panel.
The cigar lighter outlet is secured by a snap fit
within the instrument panel.
The cigar lighter knob/heating element, and the
cigar lighter outlet are available for service. These
components cannot be repaired and, if faulty or dam-
aged, they must be replaced.
VA8W-97 POWER DISTRIBUTION 8W - 97 - 1

OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell
is connected to ground, and an insulated contact in
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a
fuse in the fuseblock only when the ignition switch is
in the Accessory or On positions.
The knob and heating element are encased within
a spring-loaded housing, which also features a sliding
protective heat shield. When the heating element is
inserted in the receptacle shell, the heating element
resistor coil is grounded through its housing to the
receptacle shell. If the cigar lighter knob is pushed
inward, the heat shield slides up toward the knob
exposing the heating element.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold
the heating element against the insulated contact
long enough for the resistor coil to heat up and glow.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that
the heating element is recessed and shielded around
its circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For cigar lighter outlet diagnosis and testing pro-
cedures (Refer to 8 - ELECTRICAL/POWER DISTRI-
BUTION/POWER OUTLET - DIAGNOSIS AND
TESTING)
REMOVAL
For cigar lighter outlet removal procedure (Refer to
8 - ELECTRICAL/POWER DISTRIBUTION/POWER
OUTLET - REMOVAL).
CIRCUIT BREAKER
DESCRIPTION
Automatic resetting circuit breakers are used to
protect the power window voltage supply circuits.
These circuit breakers can protect the systems from a
short circuit, or from an overload condition caused byan obstructed or stuck power window regulator or
switch.
The circuit breaker cannot be repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The circuit breaker contains a bi-metal strip sand-
wiched between two contacts forming the connection
in the circuit. An overload condition causes the
bi-metal strip to heat and bend to the open position,
disconnecting current flow to the circuit. Then as the
system overload or short circuit is removed, the
bi-metal strip cools, re-establishing contact to allow
current flow to the circuit.
DIAGNOSIS AND TESTING - CIRCUIT BREAKER
For complete circuit descriptions and diagrams,
refer toWiring.
(1) Locate the correct circuit breaker in the fuse-
block. Pull out the circuit breaker slightly, but be cer-
tain that the circuit breaker terminals still contact
the terminals in the fuseblock cavities.
(2) Connect the negative lead of a 12-volt DC volt-
meter to a good ground.
(3) With the voltmeter positive lead, check both
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit
breaker is faulty and must be replaced. If neither ter-
minal has battery voltage, repair the open circuit
from the Power Distribution Center as required.
FUSE BLOCK #1
DESCRIPTION
An electrical fuse block is concealed under the
driver side steering column. The fuse block serves to
distribute electrical current to many of the electrical
systems in the vehicle. The fuse block contains blade-
type mini fuses, relays and micro processors that
enable automatic control of some of the power distri-
bution circuits throughout the vehicle.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
the steering column. A finger recess is molded into
the cover for easy removal. A fuse layout map is
molded onto the back side of the cover to ensure
proper fuse identification.
The fuse block cannot be repaired, if the fuse block
is faulty or damaged or if any internal circuit is
faulty or damaged, the entire fuse block must be
replaced.
8W - 97 - 2 8W-97 POWER DISTRIBUTIONVA

OPERATION
All of the circuits entering and leaving the fuse
block do so through the instrument panel wire har-
ness. Internal connection of all of the fuse block cir-
cuits is accomplished by an intricate combination of
hard wiring and bus bars. Internal relays and micro
processors allow the vehicle electronics to control
some of the power distribution circuits throughout
the vehicle. Refer to the Wiring section for complete
circuit diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove fuse block cover by rotating locking
screw 90É.
(3) Remove the steering column cover. Refer to the
Body section for the procedure.
(4) Unscrew fuse block connections and disconnect
all electrical connectors from the fuse block.
(5) Remove the fuse block from the steering col-
umn.
INSTALLATION
(1) Position the fuse block in the steering column.
(2) Install fuse block connections and connect all
electrical connectors on the fuse block.
(3) Install the steering column cover. Refer to the
Body section for the procedure.
(4) Install fuse block cover by rotating locking
screw 90É.
(5) Connect the negative battery cable.
(6) Set time and radio stations.
FUSE BLOCK #2
DESCRIPTION
An electrical fuse block is concealed under the
driver side front seat. The fuse block serves to dis-
tribute electrical current to many of the electrical
systems in the vehicle. The fuse block houses blade-
type mini fuses, blade-type automatic resetting cir-
cuit breakers and International Standards
Organization relays. Additional provisions are avail-
able in the fuse block for additional fuses and ISO
relays.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
the seat base. The driver side seat base also has a
snap-fit fuse access panel that can be removed for
service of the fuses and the relays. A finger recess is
molded into one end for easy removal. A fuse layout
map is molded onto the back side of the panel to
ensure proper fuse identification.
The fuse block is integral to the body wire harness.
If any internal circuit or the fuse block housing isfaulty or damaged, the entire fuse block and body
wire harness unit must be replaced.
OPERATION
All of the circuits entering and leaving the fuse
block do so through the body wire harness. Internal
connection of all of the fuse block circuits is accom-
plished by an intricate combination of hard wiring
and bus bars.
POWER DISTRIBUTION CEN-
TER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the Power Distribu-
tion Center (PDC). The molded plastic PDC housing
is located in the left front corner of the engine com-
partment, on the battery positive cable. The PDC
housing has a molded plastic cover that slides over
the PDC housing. The PDC cover is easily opened or
removed for service access.
The PDC unit cannot be repaired and is only ser-
viced as a unit with the headlamp and dash wire
harness. If the internal circuits or the PDC housing
are faulty or damaged, the headlamp and dash wire
harness unit must be replaced.
OPERATION
All of the current from the battery and the gener-
ator output enters the PDC through the positive bat-
tery cable. The PDC cover is removed to access the
battery and generator output connection B(+) termi-
nal studs. Internal connection of all of the PDC cir-
cuits is accomplished by an intricate combination of
hard wiring and bus bars. Refer to Wiring Diagrams
for the location of complete PDC circuit diagrams.
POWER OUTLET
DESCRIPTION
The power outlet is installed in the instrument
panel accessory switch plate, which is located near
the center of the instrument panel. The power outlet
base is secured by a snap fit within the instrument
panel. A plastic protective cap snaps over the power
outlet base when the power outlet is not being used.
While the power outlet is very similar to a cigar
lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the recepta-
cle shell that are used to secure the cigar lighter
heating element to the insulated contact.
The power outlet receptacle unit are available for
service. The power outlet receptacle cannot be
VA8W-97 POWER DISTRIBUTION 8W - 97 - 3

(4) With the A/C compressor clutch engaged, duct
temperature should not be less than 2É C (35É F) or
more than 12É C (54É F). The compressor clutch may
cycle, depending upon the ambient temperature and
humidity. If the clutch cycles, use the readings
obtained before the clutch disengaged.
(5) If the A/C compressor clutch has not cycled off
and the duct temperature is less than 2É C (35É F),
check the evaporator temperature sensor and circuitby performing the ATC Function Test (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - ATC FUNCTION TEST).
(6) If the air outlet temperature fails to meet the
specifications, refer to the A/C System Diagnosis
chart.
A/C SYSTEM DIAGNOSIS
Condition Possible Causes Correction
Rapid A/C compressor clutch
cycling (ten or more cycles
per minute).Very low refrigerant system
charge.See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.1. No refrigerant in the refrig-
erant system.1. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
2. Faulty fuse. 2. Check the fuses in the Power distribution
block and junction block. Repair the shorted
circuit or component and replace the fuses, if
required. Refer to Group 8.
3. Faulty A/C compressor
clutch coil.3. See A/C Compressor Clutch Coil in this
group. Test the compressor clutch coil and
replace, if required.
4. Improperly installed or faulty
evaporator temperature sensor.4. See Evaporator Temperature Sensor in this
group. Test the sensor and replace, if re-
quired.
5. Faulty A/C pressure trans-
ducer.5. See A/C Pressure Transducer in this
group. Test the sensor and replace, if re-
quired.
6. Faulty engine Control Mod-
ule (ECM).6. Refer to Group 9 - Engine Electrical Diag-
nostics for testing of the ECM. Test the ECM
and replace, if required.
Normal pressures, but A/C
Performance Test air temper-
atures at center panel outlet
are too high.1. Excessive refrigerant oil in
system.1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level,
if required.
2. Blend door cable improperly
installed or faulty.2. See Mode Door Cables in this group. In-
spect the cable for proper operation and re-
place, if required.
3. Blend-air door(s) inoperative
or sealing improperly.3. See HVAC Housing in this group. Inspect
the blend-air door(s) for proper operation and
sealing. Repair if required.
24 - 4 HEATING & AIR CONDITIONINGVA

²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the
DRBIIItaway from spark plug or coil wires to
avoid measuring error from outside interference.
4.3 WARNINGS
4.3.1 VEHICLE DAMAGE WARNINGS
Before disconnecting any control module, make
sure the ignition is9lock9position. Failure to do so
could damage the module.
When testing voltage or continuity at any control
module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the
insulation: this will damage the wire and eventu-
ally cause the wire to fail because of corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second DTC could be set, making diagnosis of the
original problem more difficult.
When replacing a blown fuse, it is important to
use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated
may result in a dangerous electrical system over-
load. If a properly rated fuse continues to blow, it
indicates a problem in the circuit that must be
corrected.
4.3.2 ROAD TESTING A COMPLAINT
VEHICLE
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
DTC or symptom condition.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not try to read
DRBIIITscreen while in motion. Do not hang
the DRBIIITfrom the rear view mirror or
operate it yourself. Have an assistant
available to operate the DRBIIIT.
Road testing is an essential step in the diagnostic
process that must not be overlooked. Along with the
diagnostic information obtained from the DRBIIIt
Scan Tool and the original customer concern, the
road test helps verify the problem was current and
any repairs performed, fixed the vehicle correctly.
Always operate and observe the vehicle under ac-
tual driving conditions.
Just as important as the road test is, there are
preliminary inspections that should be performed
prior to the road test. Always check the fluid leveland condition before taking the vehicle on a road
test. Determine if the incorrect fluid is being used,
improper fluid will result in erratic transmission
operation.
Some of the conditions of incorrect fluid level are as
follows:
²Delayed engagement
²Poor shifting or erratic shifting
²Excessive noise
²Overheating
The next step is to verify that the shift linkage is
correctly adjusted. If the shift linkage is incorrectly
adjusted, a number of complaints can result.
The TCM monitors the Shift Lever Position (SLP)
continuously. If the linkage is incorrectly adjusted,
the TCM will sense a shift lever position that is not
correct for the gear chosen by the driver. This may
cause a DTC to be set.
The following complaints may also be the result of
an incorrectly adjusted or worn linkage:
²Delayed clutch engagement
²Erratic shifts
²Vehicle will drive in neutral
²Engine will not crank in park or neutral
²Gear shift linkage will be able to be shifted
without the key in the ignition
²Not able to remove the ignition key in park
²Parking pawl will not engage properly
The shift linkage should also be adjusted when
replacing the Transmission, repairing the valve
body, or when repairing any component between the
shift lever and the Transmission.
Some questions to ask yourself when performing
the road test are as follows:
²Is the complaint or concern what you think the
problem is, based on the drivers description of the
problem?
²Is the Transmission operating normally, or is
there a real problem?
²When does the problem occur?
²Is the problem only in one gear range?
²What temperature does the problem occur?
²Does the vehicle have to sit over night for the
problem to occur?
²Does the transmission go into Limp-in mode?
4.4.4 BULLETINS AND RECALLS
Always perform all Safety Recalls and Technical
Service Bulletins that are applicable to the prob-
lem.
7
GENERAL INFORMATION